Composite materials

Abstract

Composite materials having at least one of the following desirable properties is described. Such properties include: rigidity, printability, water-proofness, pliability, recyclable, thermochromic, antimicrobial, electrically conductive, compostable or biodegradability. The composite includes a filler-containing layer and a fiber-containing layer substantially coupled together continuously across the at least one surface of the layers. These composites maybe useful in various markets including, but not limited to, construction, packaging, shipping, consumer products and medical packaging. The inventive composites provide, advantages such as reduction of environmental footprint, improved mechanical properties, usefulness / cost ratio, reduction in material costs compared to prior art, and cosmetic performance are embodied in the present invention.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application claims the benefit of U.S. Provisional Application Nos. 61 / 129,524, filed Jul. 2, 2008; and 61 / 194,330, filed Sep. 26, 2008; the contents of all of which are hereby incorporated by reference in their entirety.FIELD OF THE INVENTION[0002]The present invention relates to the field of composites. More particularly, the present invention relates to compositions, articles of manufacture and methods related to composites that are environmentally friendly.BACKGROUND OF THE INVENTION[0003]Synthetic paper or papers made with polymers and other fillers are usually described as transparent to completely opaque plastic films that are printable, writable and water resistance. The synthetic paper market has been traditionally a niche market with high profits but only few major participants. Historically, labels have dominated the market for synthetic paper. They are manufactured through various processing methods.[0004]Solid bleached s...

AI Technical Summary

Benefits of technology

[0008]Accordingly, the present invention satisfies a need in the industry for retail and / or shipping packages that are durable, cost effective, and attractive to consumers in terms of appearance, touch, and breathability, while incorporating environmentally friendly, recyclable, biodegradable, and / or compostable materials. It also satisfies a further need for composites that are useful for forming packaging, attractive retail, display, and / or shipping products that are readily machinable either at the point of manufacture (e.g., via scoring, folding, die-cutting, pressure and thermo-forming) or the point of distribution (e.g., via cartoning and gluing).

[0009]The present invention relates to composite materials having at least one of the following desirable properties such as: rigidity, printability, water-proofness, pliability, durability, flexibility, breathability, recyclable, thermochromic, antimicrobial, electrically conductive, compostable and biodegradability.

[0010]The composite material of the present invention represents a new class of composite materials and may include at least one discrete layer, or multiple alternating layers of a filler-containing layer, for example, a ground filler-containing layer, held together substantially continuously by at least one thermoplastic material and a fiber-containing layer. As mentioned above, the composite may be useful in, for example, retail and / or shipping packages that are durable and cost effective while are also attractive to consumers in terms of appearance, touch, breathability, theft resistant, and waterproofness, while incorporating environmentally friendly, recyclable, compostable, and / or biodegradable materials.

Problems solved by technology

Creating a packaging product that is both attractive to consumers and inexpensive to fabricate while also being sufficiently durable to meet the needs of retail and shipping use can be challenging.

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